Experimental and modeling analysis on the optimization of combined VVT and EGR strategies in turbocharged direct-injection gasoline engines with VNT

Abstract

The combination of a growing number of complex technologies in internal combustion engines (ICE) is commonplace, due to the need of complying with the tight pollutant regulations and achieving high efficiencies. Hence the work of calibration engineers is led by a constant increase in degrees of freedom in ICE design. In this research work, a wide analysis on the optimization of combined variable valve timing (VVT) and exhaust gases recirculation (EGR) strategies is developed, in order to reduce fuel consumption in a EURO 6 1.3l 4-stroke 4-cylinder, gasoline, turbocharged, direct-injection engine, also equipped with a variable nozzle turbine (VNT). For that purpose, a methodology which combines 1D engine simulations with limited experimental work was applied. First, the data from 25 experimental tests distributed into three steady engine operating conditions was used to calibrate a 1D model. Then, modeling parametric studies were performed to optimize VVT and EGR parameters. A total of 150 cases were simulated for each operating point, in which VVT settings and EGR rate were varied at iso-air mass flow and iso-intake manifold temperature. The optimization was based on finding the configuration of VVT and EGR systems which maximizes the indicated efficiency. All different cases modeled were also evaluated in terms of pumping and heat losses. Moreover, a deep assessment of instantaneous pressure traces and mass flows in intake and exhaust valves was given, to provide insights about the optimization procedure. Finally, the findings obtained by simulation were compared with the results from a design of experiments (DOE) composed of more than 300 tests, and the impact on engine fuel consumption was analyzed.